Architecture for Symbiotic Livestock and Biofuel Production

ABSTRACT

Methods and apparatus involve locating an algae production facility in close proximity to a livestock production facility whereby the outputs of one or both facilities promotes productivity levels in the facility. In an illustrative example, the algae production facility includes a bioreactor in fluid communication with the atmosphere inside, for example, a poultry facility, In some examples, the atmosphere inside the poultry facility may be around a substantially controlled temperature suitable for poultry. The atmosphere may further contain substantial Nitrogen-content suitable to promote algae growth. Various embodiments may symbiotically consume waste products from each facility to promote production of, for example, protein for food and algae, which may be used for animal feed, for example, and/or processed into fuel. In some examples, the algae production facility may be conveniently packaged into a module. In some examples, the module may be stored and shipped in a conventional shipping container.

This application is a continuation of U.S. Ser. No. 13/189,807 entitledArchitecture for Symbiotic Livestock and Biofuel Production to Grajcar,Z. that claims the benefit of U.S. Provisional Patent Application Ser.No. 61/367,468 filed by Grajcar, Z. on Jul. 26, 2010, also entitled“Architecture for Symbiotic Livestock and Biofuel Production,” theentire contents of each which are incorporated herein by reference.

TECHNICAL FIELD

Various embodiments relate to apparatus and methods for generatingbiofuels.

BACKGROUND

Modern societies have developed various processes to transform energyinto useful work driven by various types of fuels. For example, gasolinemay be ignited to drive pistons that deliver torque to the wheels of acar. Fossil fuels, for example, coal, may be consumed in largequantities in many electric power plants that distribute electric powerover large transmission networks. Other fuel sources may be used togenerate useful mechanical, electrical, or other type of work.

A class of fuels that may be new to fossil fuels may be referred to as abiofuel. Biofuel may be generally understood as including a type of fuelthat is generated from biomass. Biomass may generally be consideredbiological matter from living or recently living organisms that canserve as an energy source. Examples of biomass may sometimes includewaste, wood, gas, and alcohol. Concern over increasing oil prices,energy security, greenhouse gas emissions from fossil fuels, andgovernment subsidies has garnered increased interest in biofuels.

SUMMARY

Methods and apparatus involve locating an algae production facility inclose proximity to a livestock production facility whereby the outputsof one or both facilities promotes productivity levels in the otherfacility. In an illustrative example, the algae production facilityincludes a bioreactor in fluid communication with the atmosphere inside,for example, a poultry facility. In some examples, the atmosphere insidethe poultry facility may be around a substantially controlledtemperature suitable for poultry. The atmosphere may further containsubstantial Nitrogen-content suitable to promote algae growth. Variousembodiments may symbiotically consume waste products from each facilityto promote production of, for example, protein for food and algae, whichmay be used for animal feed, for example, and/or processed into fuel. Insome examples, the algae production facility may be convenientlypackaged into a module. In some examples, the module may be stored andshipped in a conventional shipping container.

Certain embodiments of a system for symbiotic livestock and biofuelproduction may achieve one or more advantages. For example, release ofnoxious waste gasses such as ammonia may be beneficially reduced andconverted to stimulating a renewable energy source based on algae. Someembodiments may advantageously capture available kinetic airflow, heat,carbon dioxide, ammonia, and various nutrients from livestock excretionsthat are normally discarded and may recycle those energies and nutrientsby redirecting them to grow algae. Consequently, the overall effect ofeach installation may be to incrementally reduce noxious gas emissions,recapture waste heat and kinetic energy, and reduce the production costof a valuable renewable fuel source. The algae production may generateoxygen and/or feed, for example, that can be redirected to enhance theatmosphere inside the poultry facility, which may promote the health andwell-being of poultry being raised as a protein food source.

In one exemplary aspect, an embodiment provides a system for producingalgae cells for use in processing biofuel which comprises a livestockproduction facility for generating livestock output from theirconsumption of feed and water, an algae production facility locatedproximate to the livestock production facility, the algae productionfacility comprising a reaction chamber for growing algae cells usinglivestock output and a conduit providing fluid connection between thelivestock production facility and the algae production facility, theconduit defining a passageway comprising an input port through whichlivestock output is received from the livestock production facility andan output port through which livestock output is discharged into thereaction chamber. A system in the sense of the embodiment is a facilitythat comprises further facilities. The system can further comprise meansfor transferring livestock output from the livestock production facilityinto the algae production facility through the conduit. The system canfurther comprise means for drying algae after being interacted withlivestock output to obtain at least partially dried biomass withsubstantial oil content. The livestock output can comprise manure,ammonia, carbon dioxide, heat and/or kinetic airflow. The system canalso comprise means for supplying energy to the system. In the system atleast a portion of the algae production facility can be located withinthe livestock production facility. The system can comprise a means forconveying algae output from the algae production facility into thelivestock production facility. The means for conveying algae output fromthe algae production facility into the livestock production facility cancomprise a second conduit connecting the livestock production facilityand the algae production facility. The system can further comprise ahousing for storing and shipping the algae production facility, whereinthe housing comprises a shipping container. The algae output cancomprise oxygen.

In another exemplary aspect, an embodiment also provides a method forproducing algae cells for use in processing biofuel, the methodcomprising providing a system comprising a livestock production facilityfor generating livestock output from their consumption of feed andwater, an algae production facility located proximate to the livestockproduction facility that comprises a reaction chamber for growing algaecells using livestock output, and a conduit connecting the livestockproduction facility and the algae production facility defining apassageway comprising an input port through which livestock output isreceived from the livestock production facility and an output portthrough which livestock output is discharged into the reaction chamber;introducing feed and water into the livestock production facility;generating livestock output based on livestock consumption of feed andwater; and, introducing livestock output into the reaction chamberthrough the conduit to promote the growth of algae cells. The method canfurther comprise drying algae after being interacted with livestockoutput to obtain at least partially dried biomass with substantial oilcontent. The method can further comprise introducing output from thegrowth of algae cells from the algae production facility into thelivestock production facility. The method can further compriseprocessing the biomass into a fuel. The method can further comprisecapturing the kinetic airflow available in the livestock productionfacility to supply energy to operate the algae production facility. Themethod can further comprise capturing the kinetic airflow furthercomprises generating electrical power to operate the algae productionfacility.

The details of various embodiments are set forth in the accompanyingdrawings and the description below. Other features and advantages willbe apparent from the description and drawings, and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawing figures depict one or more implementations in accord withthe present teachings, by way of example only, not by way of limitation.In the figures, like reference numerals refer to the same or similarelements.

FIG. 1 shows a block diagram architecture for an exemplary integratedfacility for producing livestock and biologically-derived fuels in asymbiotic manner.

FIG. 2 shows a block diagram of an exemplary integrated facility forproducing livestock and biologically-derived fuels in a symbioticmanner,

FIG. 3 depicts an exemplary architecture of an integrated facility forlivestock and algae production.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

FIG. 1 shows a block diagram architecture for an exemplary integratedfacility for producing livestock and biologically-derived fuels in asymbiotic manner.

Biologically-derived fuels, as used herein, generally may be referred toas bio-fuels.

As depicted in FIG. 1, an integrated facility 100 includes a livestockproduction facility 105 located in close proximity to an algaeproduction module 110. Each of the facilities 105, 110 may requirecertain inputs and yields certain outputs.

In the depicted example, the algae production module 110 receiveselectricity, water, and light from external sources, and furtherreceives kinetic airflow, heat (e.g., in the form of a warm airflow),carbon dioxide, ammonia and various nutrients (e.g., derived frommixture of water and livestock manure) that are already being outputfrom the livestock production facility 105. As the airflow is exposed tothe algae, it is expected that the algae will absorb a substantialamount of the carbon dioxide and release oxygen, thereby increasing theconcentration of oxygen relative to carbon dioxide in the airflowstream.

In the depicted example, the livestock production facility 105 receivesback from the algae production module 110 a supply of air with enhancedoxygen levels that may be advantageously supplied to the livestock. Theextraction of carbon dioxide and the supply of air with elevated oxygencontent are believed likely to enhance and/or generally promote thehealth and well-being of the livestock, with little additional cost.

The depicted capture of carbon dioxide and ammonia (e.g., NH3) maysubstantially reduce the rate at which these compounds are released intothe atmosphere. The reduction of such emissions, including but notlimited to carbon dioxide and ammonia, is believed likely to mitigatesome of the smell associated with a livestock production facility 105,and reduce the associated liability or cost of compliance under a carbonregulation scheme. For example, one exemplary effect may be for thealgae facility 110 to receive elevated concentrations of CO2, but toemit reduced concentrations of CO2 in the exhaust airflow stream.

In some examples, substantially proximate (e.g., adjacent) co-locationof facilities 105, 110 for livestock production and algae production maypermit each production facility 105, 110 to substantially directlyreceive as its input at least some of the outputs of the otherproduction facility. Accordingly, some examples may advantageouslycapture energy (e.g., heat, airflow kinetic energy) or pollutants (e.g.,ammonia, carbon dioxide) being released as waste output from a livestockfacility, and use those captured outputs as valuable inputs (e.g., heat,carbon dioxide, nutrients) that are believed to promote algae growthrates. In turn, some of the outputs (e.g., oxygen, edible feedsupplements) of the algae production 110 may be beneficially feddirectly back to the livestock facility 105, thereby forming a partialclosed loop within the facility 100.

Various embodiments may have one or more advantages. For example, someembodiments may be substantially reduce or eliminate storage and/oroff-site transportation of inputs (e.g., carbon dioxide, manure) in theproduction of either livestock or algae. Various embodiments may providesubstantial energy savings by re-capturing and re-using the air flow(e.g., kinetic energy) used to regulate temperature in the facilityand/or ventilate the livestock facility,

FIG. 2 shows a block diagram of an exemplary integrated facility forproducing livestock and biologically-derived fuels in a symbioticmanner.

As depicted in FIG. 2, a facility 200 includes a partially orsubstantially enclosed housing 205 in which a set of livestock 210 areraised. In close proximity to the housing 205 is an algae productionmodule 215. A forced airflow stream is driven by a blower 220 that, inthis example, may provide a negative-to-ambient pressure in the housing205, and exhaust directly out of the housing 205.

In the depicted example, the algae production module 215 includes analgal bioreactor 225. A duct or other air flow guide (shown as anoptional electrical generator) may be provided to direct the exhaustedair flow from the blower 220 to the algal bioreactor 225. In someembodiments that use a closed-loop bioreactor, for example, the CO2-richair exhausted at the blower 220 may be infused into the water thatcontains the algae by using a bubbling technique. In an open surfacereactor (e.g., tank type system), the airflow may be directed to flowover the surface of the algae.

The livestock 210 receive certain inputs (e.g., food, water, light,trace heat, air), and output certain desired “food” or other byproductsthat may be readily used (e.g., meat, eggs, fertilizer). The facility200 further outputs additional byproducts (e.g., heat, CO2, ammonia, andother nutrients that may be extracted, for example, from the forcedairflow exhausted by the housing 205, and/or at least a portion of themanure.) In various embodiments, at least a portion of the additionalbyproducts may be transferred to the algal bioreactor 225 to promote thealgae growth. For example, the algal bioreactor 225 may advantageouslyreceive vital inputs that promote the growth of algae, which inputs mayinclude, but are not limited to, waste heat, CO, and/or NH3, via theforced airflow exhausted from the livestock house 105 by the blower 220.

Certain embodiments may have one or more advantages. For example,symbiotic linkages may be realized by locating a bioreactor in closeproximity to the housing for domestic fowl to permit the direct captureand/or transfer of various wasted by-products from the livestock. Insome implementations, the smell of ammonia in the airflow exhausted fromthe livestock house 205 may be substantially attenuated to the extentthat the ammonia may be captured or absorbed as a nutrient that promotesalgae growth. Some embodiments may capture a substantial portion of heatenergy generated by the body heat of the livestock and transferred viathe forced airflow. In some examples, such recaptured heat energy maypromote faster algae growth rates in the bio-reactor with substantiallyno additional energy input or costs for heat to maintain a desiredtemperature of growth medium (e.g., water). Similarly, some embodimentsmay recapture CO2 generated by the livestock respiration and supply itto stimulate growth of algae. In some implementations, the water inputrequired for the algae reactor may be readily provided by an existingsupply of water (e.g., well, holding pond) required for the livestock.Waste water used in the production of livestock (e.g., washing eggs)may, in some embodiments, contain substantial nutrients that may beadvantageously recaptured to promote growth in the algae bioreactor.

As depicted in the figure, the exemplary facility 200 further includesan air flow path that provides fluid communication from an exhaust ofthe blower 220 to an interior volume of the algae growth module 215. Inthe depicted example, the air flow continues from the algal bioreactor225 into an evaporative dryer 230. The evaporative dryer may provide ameans for passively drying the algae with using the warm flow of air.

In an example implementation, the air flow enters the housing 205 atambient temperature ([Ta]). The air is warmed in the housing 205 forexample by the artificial lighting and body heat to a second temperature([Ta+dT1]). As the warmed air flow passes through the blower 220, thetemperature drops as the air flow is exposed to the bioreactor 225, downto ([Ta+dT1−dT2]). The temperature of the airflow changes again as itpasses through the evaporative dryer 230 to ([Ta+dT1−dT2−dT3]). In someimplementations, this cooled airflow with reduced CO2 content andenhance O2 content may be optionally recycled hack into the housing 205.

The algae production module 215 yields an output of at least partiallydried biomass with substantial oil content. This content may becollected and stored for shipment to a refinery 240 for conversion intoany of a variety of fuel types.

The livestock 210 produce “food” and manure 250, which may serve as asource of a product for use in fertilizer. The manure 250 is also richin nutrients that are desirable to grow algae. Accordingly a portion ofthe manure 250 may be directed to forming, for example, a mixture withwater that is rich in nutrients to promote algae growth.

The depicted example flow path includes an optional electric generator260 (e.g., turbine) be operated to recapture at least some of the (e.g.,kinetic) energy supplied by the blower 220. The generator 260 mayoperate to supply electricity to run a few pumps or instruments (e.g.,pressure gauge, CO2 gauge) or to operate the vents.

FIG. 3 depicts an exemplary architecture of an integrated facility forlivestock and algae production. Exemplary algae production modules 310a, 310 b, 310 c are shown to employ a two-way exchange of materials,such as those that have been described. This example shows that a numberof modular bioreactors (e.g., in a shipping container) may be parkednext to a livestock house. Selected livestock outputs are transferred topromote algae production, and selected algae outputs are transferred topromote livestock production. In this symbiotic exchange, energy ispartially recaptured and recycled so as to lower the cost of production.For example, the recapture heat energy from the livestock maysubstantially reduce or eliminate the need for additional energy inputto maintain the algae at a sufficient temperature to achieve high growthrates.

The close proximity of the livestock and algae production provide forthe lowest possible cost to transfer available outputs from one processto the other process.

Although various embodiments have been described with reference to thefigures, other embodiments are contemplated. For example, some or all ofthe algae module 215 may be located within the livestock housing 205. Insome examples, the algae module 215 may be arranged on the intake sideof the blower 220 so that forced air may be pulled through the algalbioreactor 225.

To raise healthy livestock in a cost-effective and time efficientmanner, the housing 205 receives inputs of feed, water, and electricity.In the depicted example, the electricity may be supplied to the at leastone blower units 220 arranged to exhaust air from an interior volume ofthe housing 205. The depicted example also shows that electricity may beused for artificial lighting, which may be manipulated in color and/orintensity to optimize biological development of the livestock, forexample. In some examples, the lighting may include LED lighting.

By way of example, and not limitation, the livestock 210 may includevarious types of fowl, such as chickens, ducks, or turkeys, which may behoused in the housing 205 for the primary purpose of breeding (e.g., egglayers) or for their protein (e.g., broiler chickens). Other livestock,such as cows, horses, sheep, pigs, goats, lamas, emus may be included,singly or in combination, in the livestock population 210.

At least a portion of the evaporative dryer 240 may be on the intakeside of the blower 135, in some examples, to pull air warm air throughthe bioreactor 125 and/or the dryer 135. In some implementations, morethan one evaporative dryer 135 may be arranged in series and or parallelin the airflow path driven by the blower 115 as may be needed toimplement rapid drying at a desired throughput for the algae.

In one example, oxygen-rich air may be directed via a conduit system toone or more locations in the poultry facility, for example. In oneembodiment, an oxygen bar may be established with output ports thatexhaust the oxygen-rich flow at a height similar to the water or feedoutlets. It is believed that the animals may seek out the oxygen-richexhaust. It is further contemplated that the oxygen-rich exhaust may becollected, stored and then released in a controlled manner. For example,the oxygen rich release may be controlled temporally in coordinationwith the availability of other inputs (e.g., food, light, water) toreduce the incidence of fighting over feed, for example. For example,providing oxygen-rich exhaust at a location away from feed pans mayreduce crowding at the feed pans. It is believed that in some cases itmay be likely that dominant animals may seek out the oxygen if suppliedprior to feeding, thereby affording less dominant animals moreopportunity to access feed and/or water, and thereby reducing mortalityand growth problems.

In some applications, it is believed that controlled elevation of oxygenlevels may be beneficial to the animals during certain portions of theschedule, such as in coordination with waking up or with the ramping upof light levels, for example. Accordingly, oxygen level manipulation inselective locations may be beneficial in discouraging and/or attractingthe animals to or away from selected locations. By way of example,oxygen rich content may be supplied during selected periods for layers,such as in a desired nesting location during ovation times, which mayconsequently reduce the number of eggs laid in undesirable locations(e.g., outside of the nest) where egg breakage and spoilage is morelikely.

In various examples, a system and a method of using the system forgenerating biofuels from livestock output is described. One or morealgae production facilities may be located within close proximity to alivestock facility. One or more conduits may provide fluid connectionbetween the livestock facility and the algae production facility totransfer livestock output to the algae production facility and algaeoutput to the livestock production facility. Livestock output maypromote the growth of algae cells. Algae output may promote the raisingand breeding of livestock.

In some embodiments, an algae production facility and a livestockproduction facility may be located within close proximity of each otherand connected by a conduit, such as a pipe. The locations of thesefacilities allow for the exchange of outputs (e.g., heated air, ammoniavapor, oxygen), which may conventionally treated as waste products.

In some implementations, one or more discrete streams of livestockoutput may be introduced in a reactor containing algae and an aqueoussolution. The algae, water, and livestock output may reside within areactor for a selected residence time. In some implementations, algaeand water in a reactor may be subjected to a continuous stream oflivestock output. At least a portion of the algae may be removed forbiofuel processing. The remaining portion may be used for growing morealgae cells. In some examples, a pump may be used to force livestockoutput from the livestock production facility into the algae productionfacility.

What is claimed is:
 1. A system for producing algae cells for use inprocessing biofuel which comprises: a livestock production facility forgenerating livestock output from their consumption of feed and water; analgae production facility located proximate to the livestock productionfacility, the algae production facility comprising a reaction chamberfor growing algae cells using livestock output; and, a conduit providingfluid connection between the livestock production facility and the algaeproduction facility, the conduit defining a passageway comprising aninput port through which livestock output is received from the livestockproduction facility and an output port through which livestock output isdischarged into the reaction chamber; wherein at least a portion of thealgae production facility is located within the livestock productionfacility; and a second conduit connecting the livestock productionfacility and the algae production facility to convey algae output fromthe algae production facility into the livestock production facility. 2.The system of claim 1, wherein livestock output comprises manure.
 3. Thesystem of claim 1, wherein livestock output comprises ammonia.
 4. Thesystem of claim 1, wherein livestock output comprises carbon dioxide. 5.The system of claim 1, wherein livestock output comprises heat.
 6. Thesystem of claim 1, wherein livestock output comprises kinetic airflow.7. The system of claim 1, further comprising means for supplying energyto the system.
 8. The system of claim 1, further comprising a housingfor storing and shipping the algae production facility, wherein thehousing comprises a shipping container.